Socket assembly and method of making a socket assembly

ABSTRACT

The socket assembly has a housing with an inner bore which extends from a first end to a second end. A ball portion of a ball stud is received in the inner bore. A backing bearing is disposed in the inner bore and presents a curved bearing surface in surface-to-surface contact with the ball portion. A first spring biases the backing bearing against the ball portion. The socket assembly also includes an exit bearing with a cylindrical portion that is in contact with an equator of the ball portion and a semi-spherical portion that is in surface-to-surface contact with an opposite hemisphere from the first bearing surface. A second spring biases the exit bearing into a predetermined location established by the housing. The exit bearing is movable from the predetermined location in a direction towards the second end of the housing against a biasing force of the second spring.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention is related, generally, to socket assemblies, andmore particularly, to socket assemblies for vehicle suspension systems.

2. Related Art

Socket assemblies of the type that are used in vehicle suspensionsystems typically include a ball stud which is rotatable and/orpivotable relative to a housing. Such socket assemblies typicallyinclude one or more bearings that are positioned within the housing andare in sliding contact with a ball portion of the ball stud tofacilitate the movement of the ball stud relative to the housing. Thebearings are typically made of either metal or a hard plastic material.

Such socket assemblies are typically either of the radial loaded type,compression loaded type or the tension-loaded type, depending on theconfiguration of the suspension system. In many known types ofcompression-style socket assemblies, when a radial load is applied tothe ball stud, the ball stud will try to walk up the radius of the lowerbearing, thereby reducing the surface of contact between the ball studand the lower bearing.

In some applications, two socket assemblies are installed in a singlesuspension system. For example, FIG. 1 shows an exemplary independentsuspension system wherein two socket assemblies are employed to connecta single knuckle with upper and lower control arms. Likewise, FIG. 2shows an exemplary fixed axle suspension system which also includes twosocket assemblies that join a single knuckle with a drive axle case. Ineach of these cases, the socket assemblies are aligned with one anotheralong an axis. It is important that the socket assemblies be properlyaligned within a predetermined tolerance to prevent one of the socketassemblies from carrying a greater share of the load of the vehicle thanthe other.

SUMMARY OF THE INVENTION AND ADVANTAGES

One aspect of the present invention is for a socket assembly with ahousing that has an inner bore. The inner bore extends along an axisfrom a wall at a generally closed first end to an open second end. Thesocket assembly also includes a ball stud with a ball portion which isreceived in the inner bore of the housing and with a shank portion whichprojects out of the inner bore through the open second end. The socketassembly further includes a backing bearing disposed in the inner boreand presenting a curved first bearing surface in surface-to-surfacecontact with an outer surface of the ball portion of the ball stud. Afirst spring is disposed in the inner bore and biases the first bearingsurface of the backing bearing against the ball portion of the ballstud. An exit bearing is also disposed in the inner bore of the housing.The exit bearing has a second bearing surface with a cylindrical portionthat is in contact with an equator of the ball portion of the ball studand with a semi-spherical portion that is in surface-to-surface contactwith an opposite hemisphere of the ball portion of the ball stud fromthe first bearing surface of the backing bearing. A second spring isdisposed in the inner bore of the housing and biases exit bearing into apredetermined location established by the housing. The exit bearing ismovable from the predetermined location in a direction towards the opensecond end of the housing against a biasing force of the second spring.

The movability of the exit bearing allows it to move axially relative tothe housing in a direction away from the backing bearing. This isparticularly advantageous in cases where the socket assembly isinstalled in a vehicle suspension assembly where it is axially alignedwith another socket assembly. Specifically, during installation, if theinstaller fails to properly align the two socket assemblies, the exitbearing may be unseated from the predetermined location and movedaxially towards the open second end of the housing which prevents theball stud from being constrained between the backing and exit bearings.As such, the torque required to rotate the ball stud relative to thehousing is not increased as could otherwise be the case if the exitbearing was fixed in its location. As the ball stud, the backing bearingand the exit bearing wear during their operating lives, the secondspring biases the exit bearing back into the predetermined location toallow the socket assembly to regain much of its internal clearances.

According to another aspect of the present invention, the exit bearinghas an outer surface which is frustum of a cone shaped with a firstdiameter nearest the open second end of the housing and a seconddiameter nearest the first closed end of the housing and wherein thefirst diameter is greater than the second diameter and wherein the outersurface is seated against a tapered inner surface of the housing whenthe exit bearing is in the predetermined location. The frustum of a coneshape of the outer surface of the exit bearing reduces the forcesrequired to unseat the exit bearing from the predetermined location inthe inner bore, thereby improving the improving the socket assembly'sperformance if misaligned with another socket assembly.

According to yet another aspect of the present invention, the exitbearing is in an interference fit with the housing.

According to still another aspect of the present invention, the exitbearing has an outer surface which presents a plurality of axiallyextending ridges which are spaced circumferentially from one another.

According to a further aspect of the present invention, a dust boot issealed against the housing and the ball stud for retaining a lubricantwithin the inner bore and for keeping contaminants out of the innerbore.

According to yet a further aspect of the present invention, the secondspring is at least partially embedded in an elastic body of the dustboot.

According to still a further aspect of the present invention, the firstspring is a Belleville washer.

According to another aspect of the present invention, the wall at theclosed first end of the housing presents a lubricant opening forreceiving a lubricant into the inner bore of the housing.

According to yet another aspect of the present invention, the firstbearing surface of the backing bearing presents at least one lubricantchannel for conveying the lubricant from the lubricant opening in thehousing into a gap between the backing and exit bearings.

According to still another aspect of the present invention, the exitbearing presents at least one lubricant channel.

According to a further aspect of the present invention, the secondspring is a Belleville washer.

According to yet a further aspect of the present invention, the housingpresents a shoulder which faces towards the open second end of thehousing and wherein the exit bearing abuts the shoulder when in thepredetermined location.

According to still a further aspect of the present invention, a coverplate is disposed in the inner bore of the housing adjacent the opensecond end.

According to another aspect of the present invention, the housing at thesecond open end is bent radially inwardly to trap the cover plate in theinner bore of the housing.

Another aspect of the present invention is for a method of making asocket assembly. The method includes the step of step of preparing ahousing with an inner bore which extends along an axis from a wall at agenerally closed first end to an open second end. The method continueswith the step of inserting a first spring into the inner bore of thehousing. The method proceeds with the step of inserting a backingbearing with a first bearing surface into the inner bore of the housingsuch that the backing bearing is movable in a radial direction relativeto the housing within the inner bore. The method continues with the stepof inserting a ball portion of a ball stud into the inner bore of thehousing such that a shank portion of the ball stud projects out of theinner bore through the open second end and wherein a curved outersurface of the ball portion is in sliding contact with the first bearingsurface of the backing bearing. The method proceeds with the step ofinserting an exit bearing into the inner bore of the housing such that acylindrical portion of a second bearing surface is in sliding contactwith an equator of the ball portion of the ball stud and such that asemi-spherical portion of the second bearing surface is in slidingcontact with an opposite hemisphere of the ball portion of the firstbearing surface of the backing bearing. The method continues with thestep of inserting a second spring into the inner bore of the housing andbiasing the exit bearing towards a predetermined location established bythe housing while allowing the exit bearing to move from thepredetermined location in a direction towards the open second end of thehousing against a biasing force of the second spring.

According to another aspect of the present invention, the method furtherincludes the step of inserting a cover plate into the inner bore of thehousing.

According to yet another aspect of the present invention, the methodincludes the step of deforming the housing adjacent the open second endto trap the cover plate, the first spring, the backing bearing, the ballportion of the ball stud, the exit bearing and the second spring in theinner bore of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will bereadily appreciated, as the same becomes better understood by referenceto the following detailed description when considered in connection withthe accompanying drawings wherein:

FIG. 1 is an exploded view of a known independent suspension system;

FIG. 2 is an exploded view of a known fixed axle suspension system;

FIG. 3 is a front elevation view of an exemplary embodiment of a socketassembly constructed according to an aspect of the present invention;

FIG. 4 is an exploded and cross-sectional view of the socket assembly ofFIG. 3;

FIG. 5 is a cross-sectional view of a housing of the socket assembly ofFIG. 3;

FIG. 6 is a cross-sectional view of the socket assembly of FIG. 3;

FIG. 7 is an enlarged view of a portion of FIG. 6;

FIG. 8 is another enlarged view of a portion of FIG. 6;

FIG. 9 is a cross-sectional view of the socket assembly of FIG. 3 andillustrating a flow path for grease within an interior of the socketassembly;

FIG. 10 is a front and semi-sectional view of an exit bearing of thesocket assembly of FIG. 3;

FIG. 11 is a top elevation view of the exit bearing of FIG. 10;

FIG. 12 is a cross-sectional view of an alternate embodiment of thesocket assembly;

FIG. 13 is a semi-sectional view of an exit bearing of the socketassembly of FIG. 12; and

FIG. 14 is a top elevation view of the exit bearing of FIG. 13.

DESCRIPTION OF THE ENABLING EMBODIMENT

Referring to the Figures, wherein like numerals indicate correspondingparts throughout the several views, a first exemplary embodiment of animproved socket assembly 20 (specifically, a ball joint assembly) isgenerally shown in FIGS. 3 and 4. In the exemplary embodiment, thesocket assembly 20 is configured for joining a control arm (not shown)or axle (not shown) with a knuckle (not shown) of a vehicle suspensionassembly. For example, the socket assembly 20 could find uses in eitherof the types of suspension assemblies shown in FIGS. 1 and 2. However,it should be appreciated that the socket assembly 20 could also finduses in tie rod ends or in a wide range of other automotive andnon-automotive applications.

The socket assembly 20 includes a housing 22 with an inner bore thatextends along an axis A from a closed first end 24 to an open second end26. At the closed first end 24, the housing 22 presents a lower wall 28with a lubricant opening 30 that receives a grease fitting 32 (alsoknown as a zerk fitting) for conveying a lubricant, such as grease, intothe inner bore to initially lubricate the components of the socketassembly 20 and to re-lubricate the socket assembly 20 as part ofroutine maintenance. The housing 22 is preferably made of a metal, suchas steel or a steel alloy, and may be shaped through any suitableprocess or combination of processes including, for example, forging,casting, machining from a billet, etc. In the exemplary embodiment, thehousing 22 is a cartridge for press-fitting into an opening in thecontrol arm. However, the housing could alternately be integrally formedwith another component, e.g., a control arm or a tie rod end.

As shown in FIG. 5, the inner bore of the housing 22 has a progressivelyincreasing diameter from the closed first end 24 to the open second end26. Specifically, the inner bore has a first portion 34 with a generallyconstant first diameter D₁ adjacent the closed first end 24, a secondportion 36 with an increasing diameter, a third portion 38 with agenerally constant second diameter D₂, and a fourth portion 39 with agenerally constant third diameter D₃ adjacent the open second end 26. Asshown, the third diameter D₃ of the fourth portion 39 is greater thanthe second diameter D₂ of the third portion 38, and the second diameterD₂ of the third portion 38 is greater than the first diameter D₁ of thefirst portion 34. An inner wall of the housing 22 at the second portion36 of the inner bore is curved to increase the diameter of the secondportion 36 in an axial direction towards the open second end 26. Betweenthe second and third portions 36, 38 of the inner bore, the housing 22presents a first shoulder 40 which faces towards the open second end 26,and the housing 22 presents a second shoulder 41 between the third andfourth portions 38, 39 of the inner bore.

Referring now to FIGS. 4-6, a backing bearing 42 is received in thefirst portion 34 of the inner bore and has a semi-spherically curvedfirst bearing surface 44 which faces axially towards the second open end26. The backing bearing 42 has an outer surface with an outer diameterwhich is less than the first diameter D₁ of the first portion 34 topresent a gap (shown in FIG. 7) between the outer surface of the backingbearing 42 and an inner surface of the housing 22. As such, the backingbearing 42 is allowed to float in a radial direction in the firstportion 34 of the inner bore within limits established by the innersurface of the housing 22. The backing bearing 42 also includes alubricant opening 46 which is aligned with the lubricant opening 30 ofthe lower wall 28 of the housing 22. The first bearing surface 44 of theexemplary embodiment is provided with a plurality of first grooves 48formed thereon for distributing a lubricant from the lubricant opening46 into the second portion 36 of the inner bore. As shown in FIG. 7, alower surface of the backing bearing 42 presents a plurality oflubrication channels 58 that allow the lubricant to flow into the gapbetween the backing bearing 42 and the first portion 34 of the innerbore of the housing 22 from which the lubricant is able to enter thesecond portion 36 of the inner bore.

The socket assembly 20 further includes a ball stud 50 which ispartially received in the inner bore of the housing 22. Specifically,the ball stud 50 includes a ball portion 52 that is fully disposed inthe inner bore and a shank portion 54 which projects out of the innerbore through the open second end 26. The shank portion 54 extends fromthe ball portion 52 to a distal end which is threaded for receiving anut to connect the shank portion 54 with another component, e.g., aknuckle. The ball portion 52 of the ball stud 50 has a generallysemi-spherically curved outer surface which has a similar radius ofcurvature to the first bearing surface 44 of the backing bearing 42. Theouter surface of the ball portion 52 is in sliding contact with thefirst bearing surface 44 to allow the ball stud 50 to rotate and pivotrelative to the backing bearing 42 and the housing 22 during operationof the suspension assembly. The backing bearing 42 is preferably made ofmetal, such as steel or a steel alloy.

A first spring in the form of a Belleville washer 65 is positioned inthe first portion 34 of the inner bore between the backing bearing 42and the lower wall 28 of the housing 22 for biasing the first bearingsurface 44 of the backing bearing 42 against the outer surface of theball portion 52 of the ball stud 50.

The socket assembly 20 further includes an exit bearing 65 which ispositioned in the third portion 38 of the inner bore and abuts the firstshoulder 40 of the housing 22. The exit bearing 65 is a separate piecefrom the backing bearing 42 and is spaced axially therefrom by a gap inthe second portion 36 of the inner bore. The exit bearing 65 has asecond bearing surface with a cylindrical portion 62 and asemi-spherical portion 66. The cylindrical portion 62 is in slidingcontact with an equator or centerline of the ball portion 52 of the ballstud 50. The semi-spherical portion 66 has a radius of curvature that issimilar to that of an outer surface of the ball portion 52 of the ballstud 50 and is in sliding contact with an opposite hemisphere of theball portion 52 from the first bearing surface 44 of the backing bearing42. In the exemplary embodiment, the second bearing surface 62 isprovided with a plurality of second lubrication grooves 64 fordistributing lubricant around the surface-to-surface contact areabetween the second bearing surface and the outer surface of the ballportion 52 of the ball stud 50 and for conveying the lubricant in theinner bore axially across the exit bearing 65. In the second portion 36of the inner bore, the gap between the backing bearing 42 and the exitbearing 65 acts as a lubrication reservoir, which holds the lubricant.

The exit bearing 65 has a generally flat or planar top surface 87 whichfaces towards the open second end 26 of the inner bore and a generallyflat or planar lower surface 82 that faces towards the closed first end24 of the inner bore. When the exit bearing 65 is positioned in apredetermined seating location in the inner bore of the housing 22, theflat lower surface 82 abuts the first shoulder 40 of the housing 22.

During operation of the suspension assembly, the cylindrical portion 62of the second bearing surface transfers all or substantially all of theradial forces between the ball stud 50 and the housing 22 while thebacking bearing 42 and the semi-spherical portion 66 of the secondbearing surface transfer all or substantially all of the axial forcesbetween the ball stud 50 and the housing 22.

The socket assembly 20 further includes a dust boot 70 which is sealedagainst the housing 22 and against the shank portion 54 of the ball stud50 for maintaining the lubricant in the inner bore of the housing 22 andfor keeping contaminants outside of the inner bore. The dust boot 70includes a first boot end which presents a radially outwardly extendingflange 72 with a second spring in the form of a Belleville washer 74that is embedded within a boot body 76 at the radially outwardlyextending flange 72. The boot body 76 is made of an elastic and flexiblesealing material, such as rubber or a plastic material. The radiallyoutwardly extending flange 72 of the dust boot 70 is positioned in thefourth portion 39 of the inner bore of the housing 22 and is insurface-to-surface contact with the top surface 87 of the exit bearing65.

A cover plate 78 is positioned at an opposite side of the radiallyoutwardly extending flange 72 of the dust boot 70. The housing 22 has aradially inwardly extending lip 80 which traps the cover plate 78 andthe radially outwardly extending flange 72 of the dust boot 70 betweenthe radially inwardly extending lip 80 and the exit bearing 65. Thisalso has the effect of preloading the Belleville washer 74 in the dustboot 70 to impart a preload force against the exit bearing 65 to biasthe second bearing surface of the exit bearing 65 against the outersurface of the ball portion 52 of the ball stud 50. The radiallyinwardly extending lip 80 is preferably formed into the housing 22 byswaging, or spinning, the housing 22 at the open second end 26.

As shown in FIG. 10, in the first exemplary embodiment of the socketassembly 20, the exit bearing 65 has an outer surface 83 that isgenerally cylindrical in shape and includes a plurality of axiallyextending and circumferentially spaced ridges 85, or knurls, distributedaround the outer surface 83. As shown, the ridges 85 extend axially fromthe planar top surface 87 of the exit bearing 65 to the planar lowersurface 82. The ridges 85 prevent rotation of the exit bearing 65 withinthe inner bore and relative to the housing 22.

As shown in FIG. 11, as viewed from above, an opening 88 in the planartop surface 87 of this embodiment of the exit bearing 65 is generallycircular in shape to allow the ball stud 50 to rotate relative to thehousing 22 by a substantially equal amount in all rotational directions.

Referring now to FIG. 12, a second exemplary embodiment of the socketassembly 120 is generally shown with like numerals, separated by aprefix of “1” indicating corresponding parts with the first exemplaryembodiment described above. This exemplary embodiment is distinguishedfrom the first exemplary embodiment discussed above in that the outersurface 183 of the exit bearing 165 has a frustum of a cone shape and isin contact with a tapered surface of the housing 22 to establish thepredetermined seating location for the exit bearing 165 within the innerbore of the housing 122. Specifically, the outer surface 183 of the exitbearing 165 has a first diameter nearest the open second end 126 of thehousing 122 and a smaller second diameter nearest the closed first end124 of the housing 122. The frustum of a cone shape of the exit bearing165 reduces the forces required to dislodge the exit bearing 165 fromthe predetermined seating location within the inner bore of the housing122. Referring now to FIG. 14, the exit bearing 165 of the secondexemplary embodiment is also distinguished from that of the firstexemplary embodiment by the opening 188 in the top surface 187 beinggenerally elliptical, for oval, in shape. The elliptical or oval shapedopening 188 allows the ball stud 150 (shown in FIG. 12) to rotate by agreater magnitude relative to the housing 122 (also shown in FIG. 12) inone rotational direction than in another. That is, the shape of theopening 188 constrains, or limits, the rotation of the ball stud 150 inone rotational direction as compared to another rotational direction.

Another aspect of the present invention is a method of making a socketassembly 20, such as the exemplary socket assembly shown in FIGS. 3-8.The method includes the step of preparing a housing 22 with an innerbore which extends from a wall 28 at a lower end 24 to an open secondend 26. The method proceeds with the step of inserting a first spring 56into the inner bore of the housing 22. The method continues with thestep of inserting a backing bearing 42 into the inner bore of thehousing 22 such that the backing bearing 42 is movable in a radialdirection relative to the housing 22 within the inner bore. The methodproceeds with the step of inserting a ball portion 52 of a ball stud 50into the inner bore of the housing 22 such that a shank portion 54projects out of the inner bore through the open second end 26 andwherein a curved outer surface of the ball portion 52 is in slidingcontact with a first bearing surface 44 of the backing bearing 42. Themethod continues with the step of inserting an exit bearing 65 into theinner bore of the housing 22 such that a cylindrical portion 62 of asecond bearing surface of the exit bearing 65 is in sliding contact withan equator, or centerline, of the ball portion 52 of the ball stud 50and such that a semi-spherical portion 66 of the second bearing surfaceis in sliding contact with an opposite hemisphere of the ball portion 52from the first bearing surface 44 of the backing bearing 42. The methodproceeds with the step of inserting a second spring 74 into the innerbore of the housing 22 and biasing the exit bearing 65 towards apredetermined location established by the housing 22 while allowing theexit bearing 65 to move from the predetermined location in a directiontowards the open second end 26 of the housing 22 against a biasing forceof the second spring 74. The method may also include the steps ofinserting a cover plate 78 into the inner bore of the housing 22 anddeforming (such as through swaging) the housing 22 adjacent the opensecond end 26 to trap the cover plate 78, first spring 56, backingbearing 42, ball portion 52 of the ball stud 50, exit bearing 65 andsecond spring 74 in the inner bore of the housing 22.

It should be appreciated that the use of the terms “upper” and “lower”herein is in reference to the orientation of the socket assembly 20 inthe Figures and is not to be interpreted as requiring a particularorientation or in any way be limiting.

Obviously, many modifications and variations of the present inventionare possible in light of the above teachings and may be practicedotherwise than as specifically described while within the scope of theappended claims.

What is claimed is:
 1. A socket assembly, comprising: a housing with aninner bore that extends along an axis from a wall at a generally closedfirst end to an open second end; a ball stud having a ball portion whichis received in said inner bore of said housing and having a shankportion which projects out of said inner bore through said open secondend; a backing bearing disposed in said inner bore and presenting acurved first bearing surface in surface-to-surface contact with an outersurface of said ball portion of said ball stud; a first spring disposedin said inner bore and biasing said first bearing surface of saidbacking bearing against said ball portion of said ball stud; an exitbearing disposed in said inner bore of said housing and presenting asecond bearing surface with a cylindrical portion in contact with anequator of said ball portion of said ball stud and with a semi-sphericalportion in surface-to-surface contact with an opposite hemisphere ofsaid ball portion of said ball stud from said first bearing surface ofsaid backing bearing, said cylindrical portion having a constantdiameter and extending axially past said equator of said ball portion ofsaid ball stud; a second spring biasing said exit bearing into apredetermined location established by said housing; and said exitbearing being movable from said predetermined location in a directiontowards said open second end of said housing against a biasing force ofsaid second spring.
 2. The socket assembly as set forth in claim 1wherein said exit bearing has an outer surface that is frustum of a coneshaped with a first diameter nearest said open second end of saidhousing and a second diameter nearest said first closed end of saidhousing and wherein said first diameter is greater than said seconddiameter and wherein said outer surface is seated against a taperedinner surface of said housing when said exit bearing is in saidpredetermined location.
 3. The socket assembly as set forth in claim 1wherein said exit bearing is in an interference fit connection with saidhousing.
 4. The socket assembly as set forth in claim 3 wherein saidexit bearing has an outer surface which presents a plurality of axiallyextending ridges that are spaced circumferentially from one another. 5.The socket assembly as set forth in claim 3 further including a dustboot sealed with said housing and sealed with said ball stud forretaining a lubricant within said inner bore of said housing and forkeeping contaminants out of said inner bore of said housing.
 6. Thesocket assembly as set forth in claim 5 wherein said second spring is atleast partially embedded in an elastic body of said dust boot.
 7. Thesocket assembly as set forth in claim 1 wherein said first spring is aBelleville washer.
 8. The socket assembly as set forth in claim 1wherein said wall at said closed first end of said housing presents alubricant opening for receiving a lubricant into said inner bore of saidhousing.
 9. The socket assembly as set forth in claim 8 wherein saidfirst bearing surface of said backing bearing presents at least onelubricant channel for conveying the lubricant from said lubricantopening in said housing into a gap between said backing and exitbearings.
 10. The socket assembly as set forth in claim 9 wherein saidsecond bearing surface of said exit bearing presents at least onelubricant channel.
 11. The socket assembly as set forth in claim 1wherein said second spring is a Belleville washer.
 12. The socketassembly as set forth in claim 1 wherein said housing presents ashoulder which faces towards said open second end of said housing andwherein said exit bearing abuts said shoulder when in said predeterminedlocation.
 13. The socket assembly as set forth in claim 1 furtherincluding a cover plate disposed in said inner bore of said housingadjacent said open second end.
 14. The socket assembly as set forth inclaim 13 wherein said housing at said second open end is bent inwardlyto trap said cover plate in said inner bore of said housing.
 15. Amethod of making a socket assembly, comprising the steps of: preparing ahousing with an inner bore which extends along an axis from a wall at agenerally closed first end to an open second end; inserting a firstspring into the inner bore of the housing; inserting a backing bearingwith a first bearing surface into the inner bore of the housing suchthat the backing bearing is movable in a radial direction relative tothe housing within the inner bore; inserting a ball portion of a ballstud into the inner bore of the housing such that a shank portion of theball stud projects out of the inner bore though the open second end andwherein a curved outer surface of the ball portion is in sliding contactwith the first bearing surface of the backing bearing; preparing an exitbearing which has a second bearing surface with a cylindrical portionand a semi-spherical portion, the cylindrical portion having a constantdiameter that extends in an axial direction; inserting the exit bearinginto the inner bore of the housing such that the cylindrical portion ofthe second bearing surface of the exit bearing is in sliding contactwith and extends axially past an equator of the ball portion of the ballstud and such that the semi-spherical portion of the second bearingsurface is in sliding contact with an opposite hemisphere of the ballportion from the first bearing surface of the backing bearing; andinserting a second spring into the inner bore of the housing and biasingthe exit bearing towards a predetermined location established by thehousing while allowing the exit bearing to move from the predeterminedlocation in a direction towards the open second end of the housingagainst a biasing force of the second spring.
 16. The method as setforth in claim 15 further including the step of inserting a cover plateinto the inner bore of the housing.
 17. The method as set forth in claim16 further including the step of deforming the housing adjacent the opensecond end to trap the cover plate, the first spring, the backingbearing, the ball portion of the ball stud, the exit bearing and thesecond spring in the inner bore of the housing.
 18. The method as setforth in claim 16 wherein the second spring is a Belleville washer. 19.The method as set forth in claim 18 wherein the second spring is atleast partially embedded within an elastic body of a dust boot.
 20. Themethod as set forth in claim 15 wherein the first spring is a Bellevillewasher.